pump pprd2 3 - e & s technologies · the pump must be positioned on its feet, as shown on the...

PPRD2 3 - - • OPERATING INSTRUCTIONS

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PUMP

PPRD2 3 - -

OPERATING INSTRUCTIONS

SAINT-GOBAIN PERFORMANCE PLASTICS ASTI SAINT-GOBAIN PERFORMANCE PLASTICS ASTI (Headquarters) (Factory) 41, boulevard des Bouvets E.A.D.A.C. des Berthilliers F-92741 NANTERRE CEDEX F-71850 CHARNAY LES MACON Tel: 33. (0) 1.55.68.59.59 Tel: 33. (0) 3.85.20.27.00 Fax: 33. (0) 1.55.68.59.68 Fax: 33. (0) 3.85.29.18.48

SAINT-GOBAIN PERFORMANCE PLASTICS

7301 Orangewood Avenue GARDEN GROVE, CA 92841

Phone: 1 (714) 630 5818 Fax: 1 (714) 688 2416

http://www.astipure.com - http://www.furon-asti.com


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INDEX Page I – General 2 I.1 – Introduction I.2 – Materials I.3 – Operation description I.4 – Control unit or PLC unit I.5 – Pump Data II – Quick Checklist 5 II.1 – Shipment II.2 – Reception III – Installation and operation 5 III.1 – Testing III.2 – Set up III.3 – Connections III.3.1 – Air/nitrogen connections III.3.2 – Fluid connections III.4 – Initial tests and adjustments IV – Applications 6 IV.1 – Chemical compatibility IV.2 – Contamination IV.3 – Temperature range IV.4 – Cleaning IV.5 – Single stroke adjustment IV.6 – Limitations of use V – Maintenance 8 V.1 – Trouble shooting V.2 – Preventive maintenance V.2.1 – Continuous operation V.2.2 – Intermittent operation V.3 – Comments VI – Dismantling and Repair 9 VI.1 – How to dismantle VI.2 – Examination VI.3 – Stripping and assembling the pump VI.3.1 – Replacing the bellow VI.3.2 – Replacing the bellow and body O.rings VI.3.3 – Replacing the check valves and manifold O.rings VI.3.4 – Replacing other parts VII – Warranty 10 Appendix: Spare parts list of the pump Section view (Drawing PPRD2 3 - - REF) General arrangement drawing (Drawing PPRD2 3 - - EXT) Wiring diagram (Drawing PPRD2 3 - - CAB)


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Thank you for selecting a SAINT-GOBAIN PERFORMANCE PLASTICS ASTI AstiPure™ model PPRD2 pump. I – General

I.1 – Introduction The model PPRD2 3 - - is a pneumatically operated TEFLON® dosing pump using an electric operating system. The pump is designed for dosing and processing of all corrosive, inflammable and sterile fluids. It meets the requirements of advanced technology industries (chemical, pharmaceutical, semiconductor, food...)

I.2 – Materials All wetted parts are manufactured in TEFLON® PFA HP and PTFE. Other parts are made of high-performance plastics such as PVDF, PEEK etc. Only piston and inductive sensors are made of steel.

I.3 – Operation description In this pneumatically operated dosing pump, there is a single TEFLON® bellow connected to a cylinder by a shaft. On the backward stroke, air/nitrogen enters the piston. On forward stroke, it enters the bellow. The cylinder is fitted with 2 mechanical stoppers. Changeover has to be achieved via an electrical delivery system (e.g. PLC or control unit) that follows the signal of both inductive sensors. The forward stroke (dose delivery phase) is followed by a backward stroke (dose preparation). At the end of each dosing cycle, the pump stops (end of suction) waiting for a new dosing cycle to be started. The pump is self-priming and has check valves, which seat on TEFLON® lip seals located in the head. The pump stroke volume is adjusted manually with a ring located at the rear of the pump. The delivery and suction speed of the pump can be adjusted independently. This varies for individual fluids (viscosity, density...) and operating conditions. The maximum pumping speed for the pump is 60 strokes/minute (when adjusted for the max. stroke unit), with a reproducibility of less than 1%.

I.4 – Control unit or PLC unit The PPRD2 3 - -pump cannot operate without an electro-pneumatic control unit or must be connected to a PLC unit. You will find hereafter the connection instructions. We can supply you a control unit (P/N 50 024 00): it is suitable for single shot and continuous operation.


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PPRD – 300 : Operating Instructions

Start

End

D=NL0S=NL1

D=NL1S=NL0

Auto cycle

Ds=NL0Ss=NL1

Ss=NL0Ds=NL1

Ss=NL1Ds=NL0

Counter

Timer

Alarm

Alarm=NL0

Beginning of pump operation

Check that the alarm is activated

Section side of air pressure. Delivery side to the exhaust

Verification of the states of the stroke sensors

Delivery side to air pressure

Suction side to the exhaust

Delivery sensor is activated

Suction sensor is desactivated

Delivery to air exhaust

Suction, to air pressure

Delivery sensor deactivated

Suction sensor is activated

Auto cycle or single shot

Jump to the alarm program

End of program

Jump to the timer

program

Jump to the counter

programYes

Yes

No

Yes

Yes

Yes

No

No

No

Yes

No

No

Ss: Suction stroke end S: suction NL0: Logic Level 0

Ds: Delivery stroke end D: Delivery NL1: Logic Level 1

S=NL1D=NL0


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Principle for PLC control according to the diagram of operating instructions: 1 - Beginning of the operation 2 - Check that alarms are not detected 2a - A solenoid valve can be used to stop the pump operation 3 - Activation of the states of the solenoid valve 3a - S=NL1: force the solenoid valve to supply the suction of the pump on standby position 3b - D=NL0: force the solenoid valve to put the delivery of the pump to the exhaust on standby

position 4 - Verification of the states of the stroke sensors 4a - Ss=NL1: the suction sensor must be activated 4b - Ds=NL0: the delivery sensor must be desactivated 5 - Start the delivery of the pump 5a - D=NL1: force the solenoid valve to supply the delivery of the pump 5b - S=NL0: force the solenoid valve to put the suction of the pump to the exhaust 6 - Verification of the states of the stroke sensors 6a - Ss=NL0: the suction sensor must be desactivated 6b - Ds=NL1: the delivery sensor must be activated 7 - Start the suction of the pump 7a - S=NL1: force the solenoid valve to supply the suction of the pump 7b - D=NL0: force the solenoid valve to put the delivery of the pump to the exhaust 8 - Verification of the states of the stroke sensors 8a - Ss=NL1: the suction sensor must be activated 8b - Ds=NL0: the delivery sensor must be desactivated 9 - Type of control 9a - Single shot 9b - Auto cycle (different control systems can be added: counter, timer, etc…) 10 - End of program. Notes: For each negative test during the program, we can have a customized alarm program. We can add to the test a timer in order to control the speed of the operation, coupled to the alarm program: - Detection of a sudden increase of back pressure, - No end sensor detection, - Absence of liquid in the installation: the pump will run much faster. Each time the pump is stopped (alarm or not), the cycle has to be restarted from the beginning of the sequence. Warning: Do not put any timer between the end sensor activation and the piloting of the solenoid valve. Detect the end sensor signal on rising wave front.


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I.5 – Pump data

The main characteristics of the PPRD2 3 - - pump are: • Reproducibility less than 1% • Single shot from 8 to 80 ml per stroke • Pumping speed max. 60 strokes/min. • Air/nitrogen pressure 43.5 to 72.5 PSI (3 to 5 bar) • Delivery pressure 58 PSI maximum (4 bar) • Suction height 6.5 feet water column (2 meters) • Product viscosity 1000 cpo max. • Temperature range from 32°F (0°C) up to 212°F (100°C) • Max. air consumption 3.5 SCFM TPN (6 m³/h) • Fluid connection TEFLON® tubing Ø 5/16"x3/8" (8x10 mm) or 3/8"x1/2" (10x13 mm) • Pump air connection Tube 3/32’’x5/32" (2.5x4 mm) • PLC or Control unit connection 2 Wires 10…30 VDC / 200 mA max. • Weight of the pump / control unit 6 lbs (2.8 kg) / 6 lbs (2.8 kg) • Overall dimensions of the pump 313x133x244 mm II – Quick Checklist

II.1 – Shipment Our pumps and control units are cleaned, sealed in plastic bag, and packed in an individual carton.

II.2 – Reception On receipt of the pump, check: • The carton has not been damaged in transit. If there are signs of damage, you should report this

immediately to the carrier. • The pump is not damaged. If there are signs of damage you should report this immediately your

local distributor. • The parts and operating instructions are included in the carton with the pump. III – Installation and Operation

III.1 – Testing All pumps are factory tested in our clean room for: • Maximum and minimum stroke, • Delivery pressure and suction head, • Pumping speed, • Reproducibility, • Leak tightness.

III.2 – Set up The pump must be positioned on its feet, as shown on the general arrangement drawing. If not, the pump body will not fill properly. The control unit or the pneumatic valve must be positioned within 5 feet (1.5 meter) from the pump (inter-connecting piping is included).


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III.3 – Connections

III.3.1 – Air/nitrogen connections

The control unit or the pneumatic valve must be connected to a regulated and filtered (20 µm) air or nitrogen supply with a max. 5/32" (4 mm) OD tube (See drawing PPRD2 3 - - CAB). Air/nitrogen pressure should be between 43.5 and 72.5 (3 and 5 bar PSI). For the best results, we recommend 58 PSI (4 bar) air/nitrogen pressure. Connections between unit and pump are made using FEP tubes. We supply these tubes. To make it easier, these tubes are color-coded. Please report to the enclosed wiring diagram.

III.3.2 – Fluid connections The pump is self-priming. An arrow located on the pump's body shows the fluid direction. The inlet is at the bottom and the outlet at the top. Both the inlet and outlet fittings can be rotated through 360 degrees if necessary, by slightly loosening the nuts of suction elbows (P/N 6086 or 6097) and delivery elbows (P/N 6087or 6098). Two optional fittings are available: • PPRD2 308 pump is supplied with flared fittings suitable for 5/16"x3/8" (8x10 mm) TEFLON® tube.

The tube needs to be flared prior to fitting using SGPPL ASTI Forming Tool (P/N MF10810). • PPRD2 310 pump is supplied with flared fittings suitable for 3/8"x1/2" (10x13 mm) TEFLON® tube.

The tube needs to be flared prior to fitting using SGPPL ASTI Forming Tool (P/N MF11013).

III.4 – Initial tests and adjustments (only for a pump supplied with a control unit) Before commissioning the pump, we recommend to test it dry with a supply pressure of 58 PSI (4 bar) to ensure the system works correctly. For this test, proceed as follows: • Select "Cycle" on the control unit, • Push the remote control button. Cycle must be delivery, then suction. If this is not the case, please check: • Air/nitrogen pressure, • Connections between control unit and pump, • Regulators for suction and delivery speed are fully open. Before using the pump with chemicals please check: • The suction elbows (P/N 6086 or 6097) and delivery elbows (P/N 6087 or 6098) are tight, • The air/nitrogen supply is between 43.5 and 72.5 PSI (3 and 5 bar), • The inlet and outlet fluid connections are correctly fitted and tight. IV – Applications

IV.1 – Chemical compatibility All PPRD2 pump wetted parts are manufactured in TEFLON® PTFE and PFA and are suitable for pumping even the most corrosive concentrated chemicals: H2SO4, HNO3, HF, H3PO4, HCl, NH4OH, KOH, NaOH, CH3COOH, TMAH, H2O2... The viscosity of the liquids must be less than 1000 cpo. PPRD pumps can pump liquids containing particles up to 0.02" (0.5 mm). Very abrasive liquids are not recommended. Please call SGPPL ASTI if you require information on chemical compatibility.


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IV.2 – Contamination

The "all plastic" construction of the PPRD pump wetted parts ensures no ionic contamination of the chemical, even if there is a bellow failure.

IV.3 – Temperature range The pump can handle liquids from 32°F (0°C) up to +212°F (100°C). When the fluid temperature is greater than 140°F (60°C) you must frequently check that the body ring (P/N 2742) and the suction and delivery elbows are fully tight and that supply pressure is less than 43.5 PSI (3 bar). For special applications call SGPPL ASTI (or your local distributor).

IV.4 – Cleaning The plastic design of the PPRD2 pump wetted parts allows the use of any cleaning materials. When flushing the pump, it is better to adjust it for maximum flow per stroke so that bellow is thoroughly cleaned.

IV.5 – Single stroke adjustment To adjust the stroke, please proceed as follows: 1) Check fluid connections, 2) Position the selector switch on "cycle", 3) Rotate the ring (P/N 6063) using the graduation located on the upper part to reach approximately

the required stroke, 4) Prime the pump by pressing the remote control command button several times, 5) When the pump cylinder is full (no more air bubbles visible), depress the control button ten times

consecutively, 6) Check the delivered volume of liquid with a calibrated beaker, test tube or a precision balance to

calculate the single stroke, 7) If unit stroke is not as required, screw on the ring (P/N 6063) to reduce the stroke, or unscrew it to

increase the volume (one ring rotation equals ± 6 ml), 8) Repeat the stroke adjustment as per 5) until you get the required volume of liquid per shot. Now, your pump is ready to run. Suction and delivery speeds can be adjusted while the pump is running with the regulators located on the control unit. CAUTION: This operation will affect the stroke volume. Once you have reached the required stroke, the stroke volume is reproducible to less than 1%. Nevertheless, we recommend checking the stroke volume regularly, especially if external conditions are varying (backpressure, suction head, temperature, fluid...).


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IV.6 – Limitations of use

To obtain the best results from your pump, you should not: • Operate the pump below 43.5 PSI (3 bar) or over 72.5 PSI (5 bar), • Use tubes longer than 5 feet (1.5 meter) between pump and control unit/pneumatic valve, • Restrict suction side (valves, filters...), • Connect the pump inlet with liquid under pressure, • Exceed the maximum or minimum temperature limits, • Pump too viscous or abrasive liquids, • Try to adjust the unit stroke beyond the specified range of 8 to 80 ml, • Exceed the pumping speed of 60 strokes/minute. • Forget to respect connection specifications (see encl. diagrams). Any of the above may be detrimental to the normal operation and life expectancy of the pump/control unit and may invalidate the warranty. If the pump is being used with very corrosive chemicals and is left for extended periods not in use, we recommend the system is emptied and flushed. V – Maintenance

V.1 – Trouble shooting If the pump stops for any reason, check: • The air/nitrogen supply, • That all valves in the chemical line are open, • That all inlet and outlet regulators are open, • That connections and wires between pump and control unit/pneumatic valve are in good condition. If there are no apparent problems, you should dismantle the pump. Beforehand, ensure that: • The air/nitrogen supply is "OFF", • The delivery tube is not under pressure, • All valves in the fluid line are closed, • You are following your local Health and Safety Regulations with regard to the particular

chemical.

V.2 – Preventive Maintenance

V.2.1 – Continuous Operation When the pump is used continuously, it is necessary to replace the following parts every year: • Bellow P/N 6092 • Bellow O.ring P/N 2724 • Body O.ring P/N 2738 • Manifold O.rings P/N 2464 • Lip seals P/N 2759

V.2.2 – Intermittent operation If the pump is used intermittently, we recommend the same parts are replaced every 18 months, and that the other parts are examined at the same time. If the pump is left standing full of chemical for long periods, we recommend you change all the Viton O.rings.


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V.3 – Comments

If the pump is used to deliver hot chemicals in excess of 140°F (60°C) the preventive maintenance schedule should be: • Every 6 months check as for continuous operation, • Every 9 months check as for intermittent operation. The above is based on SGPPL ASTI's experience. SGPPL ASTI cannot be held responsible for premature failures if the pump is misused or damaged due to an incorrect application. VI – Dismantling and Repair

VI.1 – How to dismantle Before dismantling the pump and unit, refer to the Maintenance schedule V.1, and proceed as follows: • Disconnect the air/nitrogen supply of the control unit/pneumatic valve, • Disconnect connections between the pump and the control unit/pneumatic valve, • Unscrew the nuts to remove the inlet and outlet connections (beware of any chemical droplets

remaining on the inside), • Empty the pump body, • Rinse the outside of the pump with DI water to remove all trace of chemicals.

VI.2 – Examination To comply with your local Health and Safety Regulations it is essential the pump and all parts are thoroughly cleaned both on the inside and outside. See V.2 for the Preventive Maintenance Schedule. To repair the pump, refer to schedules V.1 and V.2.1. We advise you to always check the control unit and the pump at the same time.

VI.3 – Stripping and assembling the pump

VI.3.1 – Replacing the bellow Proceed as follows to replace the bellow: 1) Unscrew the body ring (P/N 2742) with a strap wrench while holding the PFA body (P/N 6093)

with one hand, 2) Remove the PFA body (P/N 6093), 3) Now you can reach the bellow (P/N 6092); before you screw it off from the shaft (P/N 6119), block

the rotating shaft by introducing a rod Ø 4x150mm in the hole located on the backward housing (P/N 6121 – see figure). Then block the piston (P/N 6067) with the rod and unscrew the bellow,

4) Replace with the new bellow (moderately hand tighten), and remove the rod, 5) To re-assemble follow the above instructions in reverse order.

Rod


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All TEFLON® PTFE and PFA parts are soft; please handle with care to avoid damage. Do not put them down on their sealing surfaces. To re-assemble the PFA body, hand tighten the body ring (P/N 2742) and block it up by giving 1/8 further turn with a strap wrench.

VI.3.2 – Replacing the bellow and body O.rings After removing the bellow (see VI.3.1 step 3), remove the bellow O.ring (P/N 2724) and the body O.ring (P/N 2738). Then carefully replace the new ones without scratching the surface of the bellow (P/N 6092) or body (P/N 6093).

VI.3.3 – Replacing the check valves and manifold O.rings 1) Remove the suction elbows (P/N 6086 or 6097) and delivery elbows (P/N 6087 or 6098), 2) Remove the 2 manifold O.rings (P/N 2464), 3) Take off the delivery check valve (P/N 6091), 4) Pull out the delivery and suction lip seals (P/N 2759), 5) Remove the suction check valve (P/N 6091), 6) Replace the delivery lip seal (lip towards the outside of the body) using a TEFLON® rod Ø 25mm, 7) Insert the suction check valve (tip downwards) and fit the new suction lip seal (lip towards the

inside of the body), 8) Fit the manifold O.ring (P/N 2464), 9) Position the delivery check valve spring in the elbow (tip downwards) and tighten the delivery

elbow, 10) Fit the suction elbow (P/N 6086 or 6097).

VI.3.4 – Replacing other parts When dismantling the pump or control unit for service, components found damaged should be replaced. Alternatively, the pump/control unit can be returned to your distributor or SGPPL ASTI for examination, estimate, and repair. Caution: Please indicate what chemical was handled, the frequency of use, and the reason for returning the pump. A receipt note "Conditions of use" is at your disposal. Do not hesitate to ask for it when needed. An estimate for repair will be proposed to you and the pump will be returned to you within one week from date of its acceptance. VII – Warranty SGPPL ASTI pumps and accessories are warranted for all parts and labor against faulty workmanship (return to factory) for one year from delivery date (9000 hours of use). SGPPL ASTI is not responsible for damage to its products through improper installation, maintenance, use or attempts to operate them beyond their mechanical capability, intentionally or otherwise, or for unauthorized repair. SGPPL ASTI shall not be liable for any indirect, special, incidental or consequential damages resulting from the use, failure or malfunction of any product.

® Teflon and Kalrez Du Pont's registered trademarks ™ AstiPure Saint-Gobain Performance Plastics Asti trademark

PPRD2 3 - - • SPARE PARTS LIST

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SAINT-GOBAIN PERFORMANCE PLASTICS ASTI 41 boulevard des Bouvets F- 92000 NANTERRE Tel: +33 (0) 1.55.68.59.59 Fax: +33 (0) 1.55.68.59.68 http://www.astipure.com http://www.furon-asti.com

PUMP PPRD2 3 - - PART NUMBER DESIGNATION QUANTITY PPRD2 . . . 308 310 1028 CAP 5 5 1720 FLAT PLATE O.RING 4 4 2464 MANIFOLD O.RINGS 2 2 2606 SCREW 5x20 4 4 2724 VITON BELLOW O.RING 1 1 2726 VITON O.RING 1 1 2729 SCREW + WASHER 4 4 2738 FEP BODY O.RING 1 1 2742 BODY RING 1 1 2759 LIP SEAL 2 2 5008 CONNECTOR Ø 4 2 2 6061 CYLINDER BODY 1 1 6063 CENTRAL RING 1 1 6064 BACKWARD HOUSING 1 1 6068 CONNECTOR 1/4” 2 2 6070 RED INDICATOR 1 1 6072 SLIDING SLEEVE 2 2 6085 PISTON COMPOSITE RING 1 1 6086 SUCTION ELBOW TUBE 10x13mm 1 6087 DELIVERY ELBOW TUBE 10x13mm 1 6089A BLADED PLATE 1 1 6091 CHECK VALVE 2 2 6092 BELLOW + INSERT 1 1 6093 PUMP BODY 1 1 6094 CORE 1 1 6095 STICKER 8-80 ML 1 1 6096 CAP 1/4" 2 2 6097 SUCTION ELBOW TUBE 8x10mm 1 6098 DELIVERY ELBOW TUBE 8x10mm 1 6100 GREY WASHER 1 1 6101 WHITE WASHER 1 1 6102 GREEN WASHER 1 1 6104 RED WASHER 1 1 6119 SHAFT 1 1 6121 PISTON PIN 1 1 6122 SHAFT CAP 1 1 6123 PISTON 1 1 6124 SLIT SPACER FOR SENSOR 2 2 6125 FASTENING SEAL 2 2 6126 SCREW 1 1 6127 INDUCTIVE SENSOR 2 2 6129 MOVABLE STOPPER 1 1

PPRD2 3 - - • SPARE PARTS LIST

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SAINT-GOBAIN PERFORMANCE PLASTICS ASTI 41 boulevard des Bouvets F- 92000 NANTERRE Tel: +33 (0) 1.55.68.59.59 Fax: +33 (0) 1.55.68.59.68 http://www.astipure.com http://www.furon-asti.com

PUMP PPRD2 3 - - PART NUMBER DESIGNATION QUANTITY PPRD2 . . . 308 310 6131 TUBE 1 1 7135 VITON O.RING 1 1 7135F SHAFT COMPOSITE O.RING 3 3 7139 PNEUMATIC VITON O.RING 6 6 7220 PTFE SLEEVE 1 1 MS10406 NUT TUBING 4x6mm 2 2 MS10810 NUT TUBING 8x10mm 2 MS11013 NUT TUBING 10x13mm 2 TE 1/4” M TUBE 4 4

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